<VV> Mfr shoots self in foot. (long - please do not quote whole thang - minimal corvair)

[Padgett]

For about a year now I have been troubleshooting an intermittent ABS fault 
in the '88. Before going further, this was a German TEVES Mk II unit that 
was standard in Buick Reatta and Pontiac Bonneville SSEs & STEs, and 
optional in most large GM cars from 1987 to 1990. Quite a few sold.

Meanwhile I was getting intermittent fault codes 32, 36, and 76 all of 
which indicated the passenger side front wheel sensor. Checked GM service 
manuals (four from different cars and years, Ford Thunderbird listing ( 
http://www.albeedigital.com/supercoupe/articles/abs-system.html ) and a 
similar Autozone listing. All same though frustrating (four different 
codes, 32, 36, 46, 56, and 76 all said just "Right Front Wheel Sensor". 
Even verified that their right was my right (passenger side)).

Long story short at various times I replaced the wheel sensor (twice), the 
ABS computer (in trunk), the ABS relays, the wheel bearing (felt some 
play), verified the wiring harness, and finally built a replacement wiring 
harness run from 16 gauge shielded twisted pair. Had also instrumented 
several times but looked fine.

Keep in mind that the problem never surfaced while parked, only when 
driving and reading the codes required removing a cover, jabbering two 
connectors (different pins 87-88 and 89-90), and counting flashes.

Finally in desperation I just pulled the right front wheel sensor connector 
and turned the ignition on. Checking codes I found a 33. 33!?!?!?!. *Every* 
piece of documentation said that was the right *rear* sensor. Hokay, I 
cleared the codes and dug the *left* (drivers) side connector out from the 
harness and pulled it. Code 36. OY!

Hokay, maybe the computer is confused so swapped computers (no memcals, all 
different). Codes came up the same.

Careful cleaning and checking of the driver's side wheel sensor cable 
revealed a cut in the insulation and a break in the ground shield. 
Replacement cured the problem and has been fine since.

Have sent an e-mail to Continental-Teves but no reply (over a week). 
Checking found no TSB or Advisory or correction to the troubleshooting 
chart. Seems incredible that no one has noticed in 18 years. OTOH I have 
heard of a lot of TEVES ABSs being tossed out in favor of a conventional 
non-ABS system. Is one case where a mechanic just replacing all four 
sensors would win.

Interesting, but stupid.

Padgett